Electrical connector assembly and method of making same

ABSTRACT

The disclosure relates to an electrical connector assembly comprising a strip of dielectric material from which integral tubular members extend. A heat stabilized plastic insert is positioned within each tubular member, either in strip form or otherwise. Electrical terminal members are positioned within the sleeve to form electrical connectors for connection with conductive members, the strip defining a feeding device for feeding the connectors in the crimping areas of crimping devices.

United States Patent [72] Inventor Joseph Agusta Wise Mechanicshurg Pa.

[21] Appl. No. 37,609

[22] Filed May 15, 1970 [45] Patented Jan. 11, 1972 [73] Assignee AMP Incorporated Harrisburg, Pa.

[54] ELECTRICAL CONNECTOR ASSEMBLY AND METHOD OF MAKING SAME 6 Claims, 5 Drawing Figs.

[52] US. Cl 339/213 T, 339/223 R, 339/276 T [51] Int. Cl I-10lr 13/50 [50] Field of Search 339/258 S, 213, 223, 276, 256 S; 174/84, 91, DIG. 5; 16/128 5 6] References Cited UNITED STATES PATENTS 3,550,856 12/1970 Wise etal.

3,123,663 3/1964 Muldoon 339/276 T 3,163,485 12/1964 Kruitnagen et a1. 339/276 SF 2,964,171 12/1960 Chadwick 339/276 FS Primary Examiner-Marvin A. Champion Assistant Examiner- Robert A. Hafer AttorneysCurtis, Morris and Safford, William J. Keating,

Ronald D. Grefe, William Hintze, Adrian J. La Rue, Frederick W. Raring, Jay L. Seitchik and John P. Vandenburg ABSTRACT: The disclosure relates to an electrical connector assembly comprising a strip of dielectric material from which integral tubular members extend. A heat stabilized plastic insert is positioned within each tubular member, either in strip form or otherwise. Electrical terminal members are positioned within the sleeve to form electrical connectors for connection with conductive members, the strip defining a feeding device for feeding the connectors in the crimping areas of crimping devices.

ELECTRICAL CONNECTOR ASSEMBLY AND METHOD OF MAKING SAME This invention relates to electrical connectors, and, more specifically, to an electrical connector assembly including a feed carrier strip having electrical connectors carried thereby.

Electrical connectors in strip form have been well known in the art. One particular such connector which has found substantial commercial success is described in the application of Wise et al., Ser. No. 742,426, filed 'July 3, 1968. In this application, a tubular member of suitable dielectric material is extruded as a continuous strip which is provided with at least one projection extending outwardly therefrom, the dielectric tubu lar being cut, thereby forming spaced sleeves along the projection and providing the projection with means for engagement by feed means to feed the sleeves into crimping dye means of a crimping means, and placing connector components in the sleeve to form a connector assembly. This connector as sembly, however, has suffered the problem that the extruded tubular member of dielectric material has a tendency to close over the edge of the final connector when heated. This problem is known in the art as necking back. This problem has been found to present in operating areas of 80 to l C. as well as in other ranges.

I The present invention overcomes the drawbacks of the prior art as exemplified above wherein, after formation of the tubular member, a sleeve of stabilized plastic is positioned within the tubular member. The remaining steps as exemplified in the above described application can then be performed to provide the completed connector. The resulting connector displays a significant increase in temperature operating efficiency, especially in the range from 80 to l05 C. wherein the problem of necking back is substantially eliminated. V

It is therefore an object of this invention to provide an elec-' trical connector assembly and method of making same having a heat stabilizer sleeve positioned between the tubular dielectric material and the connector member.

It is a further object of this invention to provide an electrical connector assembly capable of retaining its shape under elevated operating conditions.

It is a yet further object of this invention to provide an electrical connector assembly which eliminates the problem of necking back" at elevated temperatures.

The above objects and still further objects of the invention will become immediately apparent to those skilled'in the art I after consideration of the following preferred embodiment thereof which is provided by way of example and not by way of limitation wherein: Y

FIG. 1 (FIG. 11 of prior application) is a perspective view of an extruded tubular strip 'member and projections after having undergone a cutting operation for use in the method of the present invention;

FIG. 2 (similar to FIG. 7 of parent case) illustrates the insertion of a heat stabilized sleeve into the dielectric sleeves of the carrier member of FIG. 1;

FIG. 3 illustrates the insertion of a terminal component in the sleeves already inserted in the dielectric carrier;

FIG. 4 is a view in elevation of the final connector assembly in strip form; and

FIG. 5 is a cross sectional view taken along the line 55 of FIG. 4.

FIG. 1 illustrates a continuously extruded strip 1 such as that of FIG. 4 of said copending application of Wise et al., Ser. No. 742,426, which is subjected to a cutting operation to form carrier strip 19 having oblong holes 20 therealong and sleeves 21 connected to strip 19 via extensions 22. Housings 21 are subjected to forming operations by forming dies to form an interior funnel mouth 23 at the trailing ends of the housings at one station. At a further station, the interior funnel end 23' and leading ends of the housings are subjected to a forming operation so that the leading ends of the sleeves are formed into a rectangular section 24 into which a heat stabilized sleeve 9 will be positioned followed by a connector 26 liavirig receptacle portion 25 and ferrule portion 27, the connector 26 being positioned within the sleeve 9, and the funnel end is reshaped to a bell mouth 23.

FIGS. and 3 illustrate the carrier members of FIG. 1 being subjected to an assembly operation after the cutting operation to form the connector assembly'of FIGS. 4 and 5. The holes in carrier strip 19 are engaged by teeth 6 of sprocket wheel 7 to move housings 21 of the carrier member into position in alignment with mandrel 8 on which is disposed a heat stabilized sleeve 9 which can be of any heat stabilized material such as nylon, a thermostat material and the like. Mandrel 8 is reciprocably moved to insert sleeve 9 into a housing 21 in alignment therewith. An adhesive can be applied within housing 21 or along the exterior of sleeve 9 and the two secured together in such a manner. However, 2-4 percent shrinkage of the housing will occur and an adhesive is not normally used.

I-IOusings 21 with sleeves'9 therein are moved via teeth 11 and sprocket wheel 12 to another station, illustrated in FIG. 3, whereat reciprocal mandrel 13 inserts connector component 26 into a leading end of housing 21 and sleeve 9 in alignment therewith, the connector component 26 remaining within sleeve 9 under the influence of a clinching operation or by friction. Once connector components 26 have been inserted into housing 21 and sleeve 9, the housings and sleeves can be subjected to a sizing operation to secure the connector components therein. If desired, die 15 is moved via a reciprocal action into the end of housing 21 and sleeve 9 opposite the end in which connector component 26 was inserted. Die 15 enlarges the trailing end 23' of housing 21, thereby providing a bell-mouth configuration 23 thereto for engagement with insulation on electrical conductors.

After the connector assembly, as illustrated in FIGS. 4 and 5, has been completed, the connector assembly is reeled onto a reel means (not shown) so as to be used in conjunction with an applicator device for applying the connectors onto electrical conductors or the likeJFe'ed strip 19 and holes 20 define means for engagement by a conventional feed device of the applicator for feeding the connector members in successive manner into pressure crimping means of the applicator means. Carrier strip 19 provides improved reeling capabilities for reeling the continuous strip of connectors onto a reel since it will not kink on the reel means and it feeds more smoothly into the crimping area of an applicator means because the plastic material reduces the friction between the feed means and the carrier strip. Soft metal parts can be carried in housings 21 because the soft metal parts can now be obliviated as a carrier strip. 7

Referring now to FIGS. 4 and 5, there is shown the completed connector assembly. The assembly includes a carrier strip 19 having holes 20 therein, to which carrier strips are attached plural spaced housings 21, connected via extensions 22. Only one such housing is shown. The housing 21 includes a bell-mouth portion 23 having interior funnel shape 23 and a leading end rectangular portion 24. Positioned within the leading end portion 24 of the housing 21 is the heat stabilized plastic sleeve 9. A connector 26 is positioned within the sleeve 9, the connector having a ferrule end 27 which may have a bell mouth shape and a receptacle portion 25. The housing 21 may, after crimping to a wire conductor, be heat shrunk to provide a tight fit among the several components, the sleeve 9 preventing any necking back" from occurring.

Though the invention has been described with respect to a specific preferred embodiment thereof, many variations and modifications will immediately become apparent to those skilled in the art. It is therefore the intention that the appended claims be interpreted as broadly as possible in view of the prior art to include all such variations and modifications.

What is claimed is:

1. An electrical connector assembly for feeding into crimping device comprising continuous feed strip means having spaced openings therealong for engagement by feed means of the crimping device, integral housing means secured at spaced intervals along the feed strip means, a heat stabilized sleeve positioned within only a portion of said housing so as to stabilize only said portion, and electrical connector components positioned in said sleeve defining an electrical connected adapted to be severed from said feed strip means by the crimping means when the electrical connector is crimped via the crimping device onto a conductor.

2. An electrical connector assembly according to claim 1 wherein said feed strip means extends outwardly from said housing means at diametrically disposed locations.

3. An electrical connector assembly according to claim 1 wherein said housing means are connected to said feed strip means via extensions and the extensions and feed strip means are disposed in a plane extending through the axes of the housing means.

4. An electrical connector assembly according to claim 1 wherein said housing means are connected to said feed strip means via extensions and said extensions are disposed at substantially right angles with respect to said feed strip means.

5. An electrical connector assembly according to claim 1 wherein said electrical connector components are completely housed within said sleeve means.

6. An electrical connector assembly according to claim I wherein one end of said housing means has a bell-mouth configuration. 

1. An electrical connector assembly for feeding into crimping device comprising continuous feed strip means having spaced openings therealong for engagement by feed means of the crimping device, integral housing means secured at spaced intervals along the feed strip means, a heat stabilized sleeve positioned within only a portion of said housing so as to stabilize only said portion, and electrical connector components positioned in said sleeve defining an electrical connected adapted to be severed from said feed strip means by the crimping means when the electrical connector is crimped via the crimping device onto a conductor.
 2. An electrical connector assembly according to claim 1 wherein said feed strip means extends outwardly from said housing means at diametrically disposed locations.
 3. An electrical connector assembly according to claim 1 wherein said housing means are connected to said feed strip means via extensions and the extensions and feed strip means are disposed in a plane extending through the axes of the housing means.
 4. An electrical connector assembly according to claim 1 wherein said housing means are connected to said feed strip means via extensions and said extensions are disposed at substantially right angles with respect to said feed strip means.
 5. An electrical connector assembly according to claim 1 wherein said electrical connector components are completely housed within said sleeve means.
 6. An electrical connector assembly according to claim 1 wherein one end of said housing means has a bell-mouth configuration. 